I've got a part I'd like to repair if for no other reason than to be able to do it. The value is much lower than my time.
It?s a die cast mystery alu-zinc part. From what I have read the BlueDemon/AlumiWeld/MuggyWeld/DuraFix class of aluminum "brazing" rod is the way to go due to its low melting point. I've used Muggy Weld and Dura Fix rod to bond known "aluminum" in the past. Usually 6061 or 5052. It works, but you pretty much have to be able to lay down the entire repair at once and leave it to cool. I may not be able to that with this part, but that's not where I ran into a stop on this part.
The way most of these rods is used is to heat the metal until its hot enough to melt the rod. Push it around until it wets out where you need it and let it cool. On this project the base part started to melt before it got hot enough to start melting the rod. I wiped wth acetoe and brushed thoroughly first. Same way I would prep to mig weld aluminum. I told the person who asked me to repair it (my dad) and he said he expected that and not to worry about it. Still I'd like to find a way if at all possible. It bugs me. I read one website were a guy claims to be able to weld any kind of potmetal with TIG, but the only other references I found was the same guy spamming his services on various web forums.